P0A80 advice...

Thanks. My plan is to take the car out and about tomorrow then disconnect all the bus bars right when I get home so the blocks can’t equalize , then load test all the modules for (hopefully) the most accurate data before I pull battery and start moving/replacing modules.

 

Ok I will watch the temp, thanks

 

Aloha! I took the car out yesterday for about half an hour then brought it home and immediately disconnected the bus bars and load tested the modules. Data is attached and I welcome comment. The bad 5 modules from the test I did a month ago are marked in green in the module column, and the 5 modules I propose to replace now are in yellow. The first test the car had been sitting in driveway for 2+ days when I did the load test.

My plan is to move the center modules out to the ends and vice versa, and to try to pair modules in their blocks as closely in voltage as possible, and to make the blocks as close in voltage to each other as well, using the post load test data. Should be fun.

Any comments or advice appreciated!

Mahalo!
PEH

 

Been super busy with work but will be pulling battery soon. Did load test on all the modules again, identified 5 that are worse than the rest, and will replace with modules from Prolong. Also, will mix up the placement of modules, trying to get the middle modules towards the ends and vice versa. Then will do a complete Prolong charge/discharge cycle over 4-5 days and see where I stand.

Comments appreciated!

PEH

 

Pulled the HV battery out and brought inside to workbench. Removed all the modules, then reinstalled in new configuration which includes 5 refurb modules. Will put back in the car tomorrow, do the full Prolong recondition charge/discharge over 4-5 days and see where we stand.

 

Update: put the HV battery back in, made all the connections, did all the frame mounting bolts finger tight in case of issues, connected the negative lead to my 12 volt battery and car started up and ran fine. Per Dr Prius app, biggest voltage difference between blocks is 0.10 V. Connected Prolong charger and will run the full charge/discharge protocol over the next 4-5 days.

 

Just started the second discharge. I’m tracking everything so will post the Prolong data as soon as it’s done.

 

Update: I’m on the final charge/balance cycle and should finish up sometime Friday afternoon. Will let pack rest a couple hours before I try to start the engine and drive around.

-Question: would it be a good idea to load test all the modules to establish a baseline after running the Prolong with my new pack configuration and 5 new modules?

-If YES, should I test right away? After driving? Next day? Any thoughts on this appreciated.

PEH

 

OK, let the car rest for a couple hours then took it out. Did about 6-8 miles without incident in 25-35mph zones. 56-mpg! Then went out on the freeway and did two 5 mile trips at 55-60mph, no issues. 42 mpg. Headed home (about 5-6 miles, city streets) feeling good with shakedown #1, started to back up my steep drive way, and got the bell, triangle of death and "check hybrid system" on the screen. Dr Prius and Carista confirmed P0A80.

Here's some data if you're interested. The Prolong data is a pdf below. I may try disconnecting the Prolong harness and doing the same driving route tomorrow, just for fun.

 

I’m going to try bypassing the Prolong harness per ASRDogman’s post above, and then recreate my test drive from today. Hopefully I can do this Saturday morning. Will post results. We will see what happens…

 

Update…

This morning, disconnected the Prolong harness from battery and fan and recreated my test drive from yesterday. Got home and backed up my steep driveway without issue.

About an hour later, did a 15 mile freeway run, was in a store for about 45 minutes, came out and put car in reverse and got “check hybrid system”, bell, warning lights and confirmed P0A80 code. Reset it, headed home, got another P0A80 on the freeway home.

Car felt good, got about 56 mpg around town and 42 mpg on freeway at 65mph.

Comments?

PEH